Method and apparatus for inspecting joined object formed by friction stir joining

ABSTRACT

This invention provides a method for inspecting a joined region and joining strength of a joined object formed by a spot friction stir joining process. In this method, an ultrasonic wave is introduced into the joined object from a backing face  25  opposed to a joining tool plunging face  24  and the ultrasonic wave reflected from the joined object  20  is taken in. In this case, the joining region  21  and the joining strength is estimated by observing a reflected wave of the ultrasonic wave in the vicinity of a position, along a reference direction Z, corresponding to an interface  27  of two joining members, without using the reflected wave of the ultrasonic wave reflected from the joining tool plunging face, thereby inspecting the joined object based on the estimation result. Thus, influence of a concave/convex shape of a joining mark  29  formed in the joining tool plunging face  24  can be avoided, and the use of the ultrasonic wave for estimating the joined region  21  can achieve an inspection of joining quality without destroying the joined object  20.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a Continuation of application Ser. No. 12/226,206 filed Nov. 7,2008 now U.S. Pat. No. 7,861,910, which in turn is a National Phase ofApplication No. PCT/JP2007/055496 filed Mar. 19, 2007. This applicationis based upon and claims the benefit of priority from the prior JapanesePatent Application No. 2006-109071 filed Apr. 11, 2008. The disclosureof the prior applications is hereby incorporated by reference herein inits entirety.

TECHNICAL FIELD

The present invention relates to a method for inspecting and estimatinga joined region and joining strength of an object by means of anon-destructive inspection, the object being formed by joining twomembers together by using a friction stir joining method.

BACKGROUND ART

FIG. 25 is a diagram for illustrating a method for estimating a weldedregion 2 of a welded object 1 welded by a conventional resistance spotwelding. As shown in FIG. 25, the welded object 1 is formed byspot-welding an upper plate 3 and a lower plate 4 together at the weldedregion 2. In the welded region 2, the upper plate 3 and the lower plate4 are welded together due to disappearance of an interfacial portion 5,caused by melting, between the upper plate 3 and the lower plate 4. Innon-welded regions 6 except for the welded region 2 of the welded object1, the interfaces 5 remain between the upper plate 3 and the lower plate4.

The welded region 2 includes a nugget portion 7, in which the upperplate 3 and the lower plate 4 are melted and welded together, and acorona-bonded portion 8, which covers the nugget portion 7 and in whichthe upper plate 3 and the lower plate 4 are slightly melted and closelyadhered together. In the resistance spot welding, a front face 9 and arear face 10 of the welded object 1 are arranged to be substantiallyparallel with each other.

As a conventional art, there is a method for estimating the weldedregion 2 of the welded object 1 by using an ultrasonic wave. In theconventional art, an ultrasonic probe 11 adapted to generate theultrasonic wave is scanned to pass through over the welded region 2 soas to take therein a reflected wave of the ultrasonic wave reflectedfrom the welded object 1 for each scanning displacement. The reflectedwave 12 of the ultrasonic wave introduced in and reflected from thewelded object 1 will be a reflected wave reflected from a bottom face 13of the upper plate 3 in the non-welded regions 6, while it will be areflected wave reflected from a bottom face 14 of the lower plate 4 inthe welded region 2. In this conventional estimating method, boundarypositions 15 between the welded region 2 and the non-welded regions 6are estimated by comparing the reflected waves from the upper plate 13and from the lower plate 14, thus estimating a size of the welded region2.

In a technique disclosed in Patent Document 1, as an estimation of thewelded region 2 in the welded object 1, the nugget portion 7 is obtainedbased on attenuation of multiple reflection waves multiply reflectedfrom a top face 16 of the upper plate 3 and from the bottom face 14 ofthe lower plate 4. In a technique disclosed in Patent Document 2, as theestimation of the welded region 2 in the welded object 1, the nuggetportion 7 is obtained based on a level of a transverse ultrasonic wavegenerated by mode conversion that is caused when an ultrasonic wave isreflected by the bottom face 14 of the lower plate 4.

As another conventional art, there is a method for estimating a joinedregion by employing an ultrasonic wave, the joined region being formedby a continuous friction stir joining. In a technique disclosed inPatent Document 3, presence of holes indicative of a defect of joiningin the joined region is detected when amplitude of a bottom face echoreflected from a bottom face of a joined object is lower than atheoretical value. It is noted that the joined object formed by thecontinuous friction stir joining has a substantially flat front face.

-   Patent Document 1: JP 3-233352 A-   Patent Document 2: JP 2000-146928 A-   Patent Document 3: JP 2004-317475 A

As one of joining methods, there is a lap-joint-joining method utilizingthe friction stir joining method. Namely, in a lap joint formed by thefriction stir joining method, the upper plate and the lower plate arejoined together due to disappearance of the interfacial portion, whichwas stirred between the upper plate and the lower plate. Conventionally,the joined region and the joining strength of a lap-joint-joined objectformed by the friction stir joining method are obtained by a destructiveinspection, respectively. Therefore, there still remains a need for amethod and an apparatus for obtaining the joined region and the joiningstrength by a non-destructive inspection also in the case of thelap-joint joined object formed by the friction stir joining method.

However, the joined object formed by the friction stir joining methodgenerally includes a non-flat tool-processing or tool-plunging facehaving a complex concave/convex shape. Therefore, in the technique ofthe non-destructive inspection employing the reflected wave reflectedfrom the bottom face 14 of the bottom plate, the reflected wave isaffected by such a concave/convex shape of the tool-plunging face. Thismakes it difficult to obtain the joined region and the joining strengthwith respect to an object formed by a spot friction stir joining method.

DISCLOSURE OF INVENTION

Therefore, it is an object of the present invention to provide anestimation method and an estimation apparatus for estimating the joinedregion and/or joining strength of the joined object formed by the spotfriction stir joining method.

It is another object of the present invention to provide a method and anapparatus for inspecting the joined region and/or joining strength ofthe object formed by the spot friction stir joining method, withoutperforming a destructive inspection.

The present invention is a method of estimating a joined region of ajoined object in which two joining members are joined together whilebeing overlapped one on another by using a friction stir joining method,comprising:

a reflected wave measuring step of introducing an ultrasonic wave intothe joined object from a face of the joined object opposed to anplunging face thereof in which a joining tool was plunged upon afriction stir process, and taking in a reflected wave of the ultrasonicwave introduced into and reflected from the joined object; and

an estimation step of estimating an ultrasonic wave incident position asa position over the joined region, provided that among reflected wavestaken in by the reflected wave measuring step, an observed reflectedwave reflected in a vicinity of a position corresponding to an interfacebetween the two joining members satisfies a predetermined boundarycondition.

According to this invention, in the reflected wave measuring step, theultrasonic wave is introduced into the joined object from the faceopposed to the plunging face in which the joining tool was plunged,while the ultrasonic wave reflected from the joined object is taken in.In a non-joined region, because an interface between one joining memberand the other joining member does not completely disappear, theultrasonic wave introduced from the one joining member is reflected fromthe interface between the one joining member and the other joiningmember. On the other hand, in the joined region, because the one joiningmember and the other joining member are joined together and theinterface therebetween has been disappeared, the ultrasonic waveintroduced from the one joining member is transmitted into the otherjoining member without being reflected by the one joining member, assuch the reflected wave reflected in the vicinity of a positioncorresponding to the interface between the two joining members will bequite reduced or substantially lost.

Accordingly, a feature or features of the observed reflected wave willchange between the case in which the ultrasonic wave incident positionis located over the non-joined region and the case in which the sameincident position is located over the joined region. By judging whetheror not the observed reflected wave satisfies the predetermined boundarycondition, based on changing amounts of the feature's value of theobserved reflected wave, it can be estimated which of the non-joinedregion or joined region the ultrasonic wave incident position is locatedover.

In this invention, the ultrasonic wave is introduced into the joinedobject from the face opposed to the plunging face in which the joiningtool was plunged. Consequently, the ultrasonic wave can be introducedinto the joined object without being affected by the concave/convexshape formed in the tool plunging face. This can also prevent theultrasonic probe from contacting with a tool plunging mark of the joinedobject, thereby avoiding damage of the ultrasonic probe. In thisinvention, in the estimation step, the joined region is estimated byobserving the reflected wave of the ultrasonic wave reflected in thevicinity of the position corresponding to the interface of the twojoining members, without utilizing the reflected wave of the ultrasonicwave reflected from the joining tool plunging face. Thus, the joinedregion can be estimated without being affected by the concave/convexshape of the joining tool plunging face.

In this way, by estimating the joined region by using the ultrasonicwave, the quality of joining can be estimated without destroying thejoined object. Thus, the cost required for the quality inspection can bereduced as compared with the case requiring the destructive inspection.Even in the case of a large-size joined object for which the destructiveinspection is generally difficult, the joining quality can be estimatedwith ease.

In the present invention, in the reflected wave measuring step, theultrasonic wave incident position is scanned so as to pass through overthe joined region, while the reflected wave of the ultrasonic waveintroduced into the joined object is taken in for each displacement ofscanning position.

According to this invention, by scanning the ultrasonic wave incidentposition so as to pass through over the joined region, the position overthe boundary between the joined region and the non-joined region, whichwould be located on the straight line along the scanning direction, canbe estimated, thereby estimating a general size of the joined region.Consequently, the joining strength can be obtained as well asinformation necessary for works for inspecting the joining quality orthe like can be provided.

In the present invention, the boundary condition is set based on thereflected wave reflected at the interface of the two joining memberswhen the ultrasonic wave incident position is located over a non-joinedregion.

According to this invention, the boundary condition is set based on theobserved reflected wave in the case in which the ultrasonic waveincident position is located over the non-joined region. Thus, theboundary condition can be set for each joined object, and therefore thejoined region can be precisely estimated even in the case in which thereare variations of the boundary condition for each joined object.

In the present invention, in the estimation step, the ultrasonic waveincident position, in which an amplitude of the observed reflected waveis lower than a predetermined amplitude threshold value, is estimated asthe position over the joined region.

According to this invention, when the ultrasonic wave incident positionis located over the joined region, the ultrasonic wave introduced intothe joined object is transmitted from the one joining member into theother joining member. Therefore, the amplitude of the ultrasonic wavereflected from the position corresponding to the interface of the twojoining members will be relatively low. Accordingly, the ultrasonic waveincident position, in which the amplitude of the observed reflected waveis lower than the predetermined amplitude threshold value, can beestimated as the position over the joined region. Since this estimationis based on the amplitude of the observed reflected wave, there is noneed for analyzing frequencies of wave forms included in the reflectedwave, as such facilitating the estimation of the joined region.

In the present invention, in the estimation step, the ultrasonic waveincident position, in which a central frequency that is a center of afrequency distribution band of a wave form higher than an amplitudevalue lower by a predetermined amount than a maximum amplitude value inthe frequency distribution band of the wave form included in theobserved reflected wave is lower than a predetermined frequencythreshold value, is estimated as the position over the joined region.

According to this invention, in the case in which the ultrasonic waveincident position is located over the joined region, the ultrasonic waveis more likely to be transmitted from the one joining member into theother joining member, as compared with the case in which the ultrasonicwave incident position is located over the non-joined region. Among thewave forms included in the reflected wave, the wave forms in a higherfrequency band will exhibit higher directivity as compared with the waveforms in a lower frequency band. If the boundary face between the joinedregion and the remaining region not subjected to the friction stirprocess is inclined relative to the ultrasonic wave incident face on theside of the ultrasonic wave incident face, the wave forms in the higherfrequency band will be taken in, in a lesser amount, as the reflectedwave. Besides, the wave forms in the higher frequency band are morelikely to be lowered as compared with those in the lower frequency band.In view of this point, in the case in which the ultrasonic wave incidentposition is located over the joined region, the central frequency of theobserved reflected wave is lowered, as compared with the case in whichthe same incident position is located over the non-joined region.

Accordingly, the ultrasonic wave incident position, in which the centralfrequency of the observed reflected wave is lower than the predeterminedfrequency threshold value, can be estimated as the position over thejoined region. With the frequency analysis, the joined region can beprecisely estimated even in the case in which the echo level issignificantly lower as well as in the case in which considerable noiseis generated. For instance, the predetermined frequency threshold valueis set lower than the central frequency of the observed reflected wavein the case in which the ultrasonic wave incident position is locatedover the non-joined region.

In the present invention, in the estimation step, the ultrasonic waveincident position, in which a peak frequency that is a frequency of awave form exhibiting a maximum amplitude value in a frequencydistribution band of the wave form included in the observed reflectedwave is lower than a predetermined frequency threshold value, isestimated as the position over the joined region.

According to this invention, in the case in which the ultrasonic waveincident position is located over the joined region, the ultrasonic waveis more likely to be transmitted from the one joining region into theother joining region, as compared with the case in which the sameincident position is located over the non-joined region. Among the waveforms included in the reflected wave, the higher frequency wave formswill exhibit higher directivity as compared with the lower frequencywave forms. If the boundary face between the joined region and theremaining region not subjected to the friction stir process is inclinedrelative to the ultrasonic wave incident face on the side of theultrasonic wave incident face, the higher frequency wave forms will betaken in, in a lesser amount, as the reflected wave. Besides, the higherfrequency wave forms are more likely to be lowered as compared with thelower frequency wave forms. In view of this point, in the case in whichthe ultrasonic wave incident position is located over the joined region,the peak frequency of the observed reflected wave is lowered, ascompared with the case in which the same incident position is locatedover the non-joined region.

Accordingly, the ultrasonic wave incident position, in which the peakfrequency of the observed reflected wave is lower than the predeterminedfrequency threshold value, can be estimated as the position over thejoined region. With the frequency analysis, the joined region can beprecisely estimated even in the case in which the echo level issignificantly lower as well as in the case in which considerable noiseis generated. For instance, the predetermined frequency is set lowerthan the central frequency of the observed reflected wave in the case inwhich the ultrasonic wave incident position is located over thenon-joined region. In addition, due to the estimation of the joinedregion based on the peak frequency, the joined region can be estimated,even in the case in which the frequency distribution of each wave formincluded in the observed reflected wave is shifted to some extent from anormal distribution.

In the present invention, in the estimation step, the ultrasonic waveincident position, in which a frequency distribution bandwidth of a waveform greater than an amplitude value lower by a predetermined amountthan a maximum amplitude value in a frequency distribution band of thewave form included in the observed reflected wave is greater than apredetermined frequency bandwidth threshold value, is estimated as theposition over the joined region.

According to this invention, in the case in which the ultrasonic waveincident position is located over the joined region, the ultrasonic waveis more likely to be transmitted from the one joining region into theother joining region, as compared with the case in which the sameincident position is located over the non-joined region. Among the waveforms included in the reflected wave, the higher frequency wave formswill exhibit higher directivity as compared with the lower frequencywave forms. If the boundary face between the joined region and theremaining region not subjected to the friction stir process is inclinedrelative to the ultrasonic wave incident face on the side of theultrasonic wave incident face, the higher frequency wave forms will betaken in, in a lesser amount, as the reflected wave. Besides, the higherfrequency wave forms are more likely to be lowered as compared with thelower frequency wave forms. In view of this point, in the case in whichthe ultrasonic wave incident position is located over the joined region,dispersion of the frequency distribution of the wave form included inthe observed reflected wave becomes greater as compared with the case inwhich the same incident position is located over the non-joined region,as such further widening the frequency distribution bandwidth of thewave form greater than the amplitude value which is lowered by thepredetermined amount from the maximum amplitude value.

Accordingly, the ultrasonic wave incident position, in which thefrequency distribution bandwidth of the observed reflected wave isgreater than the predetermined frequency bandwidth threshold value, canbe estimated as the position over the joined region. For instance, thepredetermined frequency bandwidth threshold value is set wider than thefrequency bandwidth in the case in which the ultrasonic wave incidentposition is located over the non-joined region. With the frequencyanalysis, the joined region can be precisely estimated even in the casein which the echo level is significantly lower as well as in the case inwhich considerable noise is generated. In addition, due to theestimation of the joined region based on the peak frequency, the joinedregion can be estimated adequately, even in the case in which thefrequency distribution of each wave form included in the observedreflected wave is shifted to some extent from a normal distribution.

The present invention is a method of estimating a joining strength of ajoined object in which two joining members are joined together whilebeing overlapped one on another by using a friction stir joining method,comprising:

a reflected wave measuring step of introducing an ultrasonic wave intothe joined object from a face of the joined object opposed to anplunging face thereof in which a joining tool was plunged upon afriction stir process, and taking in a reflected wave of the ultrasonicwave introduced into and reflected from the joined object;

a joined region estimation step of, estimating an ultrasonic waveincident position as a position over the joined region, provided thatamong reflected waves taken in by the reflected wave measuring step, anobserved reflected wave reflected in a vicinity of a positioncorresponding to an interface between the two joining members satisfiesa predetermined boundary condition; and

a strength estimation step of estimating a size of the joined regionbased on the position over the joined region estimated in the joinedregion estimation step and estimating the joining strength of the joinedobject based on an estimated size of the joined region.

According to this invention, in the reflected wave measuring step, theultrasonic wave is introduced into the joined object from the faceopposed to the plunging face in which the joining tool was plunged,while the reflected wave of the ultrasonic wave reflected from thejoined object is taken in. A feature or features of the observedreflected wave will change between the case in which the ultrasonic waveincident position is located over the non-joined region and the case inwhich the same incident position is located over the joined region. Byjudging whether or not the observed reflected wave satisfies thepredetermined boundary condition, based on the feature's value of theobserved reflected wave, it can be estimated which of the non-joinedregion or joined region the ultrasonic wave incident position is locatedover.

In this invention, the ultrasonic wave is introduced into the joinedobject from the face opposed to the plunging face in which the joiningtool was plunged. Consequently, the ultrasonic wave can be introducedinto the joined object without being affected by the concave/convexshape formed in the tool plunging face. This can also prevent theultrasonic probe from contacting with the tool plunging mark of thejoined object, thereby avoiding damage of the ultrasonic probe. In thisinvention, in the joined region estimation step, the joined region isestimated by observing the reflected wave of the ultrasonic wavereflected in the vicinity of the position corresponding to the interfaceof the two joining members, without utilizing the reflected wave of theultrasonic wave reflected from the joining tool plunging face. Thus, thejoined region can be estimated, without being affected by theconcave/convex shape of the joining tool plunging face, by estimatingthe joined region without utilizing the reflected wave of the ultrasonicwave reflected by the joining tool plunging face.

In the strength estimating step, the size of the joined region isestimated, based on the estimation result obtained by the joined regionestimation step. The size of the joined region and the joining strengthis in a generally one-to-one relation. Accordingly, based on the size ofthe joined region, the joining strength of the joined object can beestimated.

In this manner, by estimating the joining strength of the joined objectby using the ultrasonic wave, the joining strength can be estimatedwithout destroying the joined object, as such reducing the cost requiredfor the quality inspection as compared with the case requiring thedestructive inspection. Additionally, even in the case of a large-sizejoined object for which the destructive inspection is usually difficult,the joining strength can be estimated.

The present invention is a method of estimating a joining strength of ajoined object in which two joining members are joined together whilebeing overlapped one on another by using a friction stir joining method,comprising:

a reflected wave measuring step of introducing an ultrasonic wave intothe joined object from a face of the joined object opposed to anplunging face thereof in which a joining tool was plunged upon afriction stir process, and taking in a reflected wave of the ultrasonicwave introduced into and reflected from the joined object, for a unitrange including a region over a joined region of the joined object; and

a strength estimation step of estimating the joining strength of thejoined object, based on an integrated feature's value of an observedreflected wave reflected in a vicinity of a position corresponding to aninterface of the two joining members, among reflected waves taken in bythe reflected wave measuring step, for the unit range, as well as on arelation of conversion which is set for converting the integratedfeature's value into a strength of the joined object.

According to this invention, in the reflected wave measuring step, theultrasonic wave is introduced into the joined object from the faceopposed to the plunging face in which the joining tool was plunged,while the ultrasonic wave reflected from the joined object is taken in.The integrated feature's value of the observed reflected wave in theunit range including a region over the joined region is changed,depending on the size of the joined region under the unit range. Sincethe size of the joined region and the strength of the joined object havea one-to-one relationship with each other, the joining strength of thejoined object can be estimated in accordance with the integratedfeature's value of the observed reflected wave in the unit range and thepreset relation of conversion. In such a manner, by estimating thejoining strength of the joined object based on the integrated feature ofthe observed reflected wave in the unit range, the joining strength ofthe joined object can be readily estimated without a need for obtainingthe size of the joined region.

Additionally, the present invention may feature that, in the reflectedwave measuring step, the ultrasonic wave is introduced into the joinedobject at a plurality of different angles of refraction.

According to this invention, even in the case in which a hookingphenomenon occurs upon the friction stir joining process, a reflectedecho from a hooking portion can be caught by an angle beam method.Therefore, the precision of estimation for the joined region and/orjoining strength can be enhanced.

The present invention is a method of estimating a joining strength of ajoined object in which two joining members are joined together whilebeing overlapped one on another by using a friction stir joining method,comprising:

a reflected wave measuring step of introducing an ultrasonic beam havinga cross section greater than a joined region diameter, by using avertical oscillator, into the joined object from a face of the joinedobject opposed to an plunging face thereof in which a joining tool wasplunged upon a friction stir process, and taking in a reflected wave ofthe ultrasonic wave introduced into and reflected from the joinedobject; and

a strength estimation step of estimating the joining strength of thejoined object, based on a reflected echo level obtained by the reflectedwave measuring step.

According to this invention, the joining strength of the joined objectcan be estimated with a simple and low-cost method.

The present invention is a method of testing a joined object in whichtwo joining members are joined together while being overlapped one onanother by using a friction stir joining method, the testing methodcomprising the step of inspecting the joined object based on anestimation result obtained by the estimation method described above.

According to this invention, the joined object is inspected based on theestimation by the estimation method described above. Consequently, theinspection for the joined region and/or joining strength can beperformed without destroying the joined object, as such facilitating theinspection work.

The present invention is an apparatus for estimating a joined region ofa joined object in which two joining members are joined together whilebeing overlapped one on another by using a friction stir joining method,comprising:

an ultrasonic probe configured to introduce an ultrasonic wave into thejoined object and also take in a reflected wave reflected from thejoined object;

probe moving means configured to scan the ultrasonic probe over a faceof the joined object opposed to an plunging face thereof in which ajoining tool was plunged, such that the ultrasonic probe passes throughover the joined region of the joined object;

scanning position detection means configured to detect a scanningposition of the probe;

extraction means connected with the ultrasonic probe and configured toextract an observed reflected wave reflected in a vicinity of a positioncorresponding to an interface between the two joining members, amongreflected waves taken in by the ultrasonic probe;

storage means configured to correlate the scanning position detected bythe scanning position detection means with the observed reflected waveextracted by the extraction means corresponding to the scanning positionand store them therein;

estimation means configured to read information stored in the storagemeans and estimate the scanning position corresponding to the observedreflected wave satisfying a predetermined boundary condition, as aposition over the joined region; and

output means configured to output an estimation result obtained by theestimation means.

According to this invention, the ultrasonic wave is introduced into thejoined object from the face opposed to the plunging face in which thejoining tool was plunged, while the ultrasonic wave reflected from thejoined object is taken in, by the ultrasonic probe. In this state, theprobe moving means scans the ultrasonic probe such that it passesthrough over the joined region of the joined object. The extractionmeans extracts the observed reflected wave, for each scanning position,during a period of time the ultrasonic probe is moved by the probemoving means. The storage means correlates the scanning positiondetected by the scanning position detection means with the observedreflected wave extracted by the extraction means corresponding to thescanning position and then stores them therein.

A feature or features of the observed reflected wave will change betweenthe case in which the ultrasonic wave incident position is located overthe non-joined region and the case in which the same incident positionis located over the joined region. The estimation means estimates thescanning position in which the observed reflected wave satisfies thepredetermined boundary condition as a position in which the ultrasonicwave incident position is over the joined region. The output meansoutputs the estimation result obtained by the estimation means.

In this invention, the ultrasonic wave is introduced into the joinedobject from the face opposed to the plunging face in which the joiningtool was plunged, while the joined region is estimated by observing thereflected wave of the ultrasonic wave in the vicinity of the positioncorresponding to the interface between the two joining members.Consequently, the joined region can be estimated, without being affectedby the concave/convex shape of the joining tool plunging face. This canalso prevent the ultrasonic probe from contacting with the tool plungingmark of the joined object, thereby avoiding damage of the ultrasonicprobe. Due to the output of the estimation result for the joined region,the quality of joining can be known without destroying the joinedobject, as such reducing the cost required for the quality inspection ascompared with the case requiring the destructive inspection.

The present invention is an apparatus for inspecting a joined object inwhich two joining members are joined together while being overlapped oneon another by using a friction stir joining method, comprising:

an ultrasonic probe configured to introduce an ultrasonic wave into thejoined object and also take in a reflected wave reflected from thejoined object;

probe moving means configured to scan the ultrasonic probe over a faceof the joined object opposed to an plunging face thereof in which ajoining tool was plunged, such that the ultrasonic probe passes throughover the joined region;

scanning position detection means configured to detect a scanningposition of the probe;

extraction means connected with the ultrasonic probe and configured toextract an observed reflected wave reflected in a vicinity of a positioncorresponding to an interface between the two joining members, amongreflected waves taken in by the ultrasonic probe;

storage means configured to correlate the scanning position detected bythe scanning position detection means with the observed reflected waveextracted by the extraction means corresponding to the scanningposition;

estimation means configured to read information stored in the storagemeans and estimate the scanning position corresponding to the observedreflected wave satisfying a predetermined boundary condition as aposition over the joined region;

judging means configured to judge whether or not the joined objectsatisfies a predetermined quality, based on an estimation resultobtained by the estimation means; and

output means configured to output a judging result obtained by theestimation means.

According to this invention, by the ultrasonic probe, the ultrasonicwave is introduced into the joined object from the face opposed to theplunging face in which the joining tool was plunged, while theultrasonic wave reflected from the joined object is taken in. In thisstate, the probe moving means scans the ultrasonic probe such that itpasses through over the joined region of the joined object. Theextraction means extracts the observed reflected wave, for each scanningposition, during a period of time the ultrasonic probe is moved by theprobe moving means. The storage means correlates the scanning positiondetected by the scanning position detection means with the observedreflected wave extracted by the extraction means corresponding to thescanning position and then stores them therein.

A feature or features of the observed reflected wave will change betweenthe case in which the ultrasonic wave incident position is located overthe non-joined region and the case in which the same incident positionis located over the joined region. The estimation means estimates thescanning position in which the observed reflected wave satisfies thepredetermined boundary condition as a position in which the ultrasonicwave incident position is over the joined region. The judging meansjudges whether or not the joined object satisfies the predeterminedquality, based on the estimation result obtained by the estimationmeans. The output means outputs the estimation result obtained by theestimation means.

In this invention, the joined region is estimated by introducing theultrasonic wave into the joined object from the face opposed to theplunging face in which the joining tool was plunged, while observing thereflected wave of the ultrasonic wave in the vicinity of the positioncorresponding to the interface between the two joining members.Consequently, the quality of the joined object can be inspected, withoutbeing affected by the concave/convex shape of the joining tool plungingface and without destroying the joined object.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a section for illustrating an estimation method for a joinedregion 21 of a joined object 20, this method being a first embodiment ofthe present invention.

FIG. 2 is a block diagram showing an estimation apparatus 30 for thejoined region 21.

FIG. 3 is a diagram showing a transfer route of an ultrasonic probe 31moved by a probe moving means 32.

FIG. 4 is a diagram showing a wave form of an ultrasonic reflected wavereflected from the joined object 20.

FIG. 5 is a diagram for illustrating changes of the wave form of thereflected wave, relative to changes of a scanning position.

FIG. 6 is a diagram for illustrating changes of an echo level, relativeto the changes of the scanning position.

FIG. 7 is a graph for showing a comparison of distribution of adiametric size of the estimated joined region 21 with the diametric sizeof the joined region 21 obtained by observation of a ruptured facethereof after estimation.

FIG. 8 is a graph for showing a comparison of the distribution of thediametric size of the estimated joined region 21 with the diametric sizeof the joined region 21 obtained by observation of the ruptured facethereof after the estimation.

FIG. 9 is a graph for showing distribution of the joining strength ofthe joined object measured by a destructive inspection, relative to thediametric size of the estimated joined region 21.

FIG. 10 is a flow chart showing a procedure of the estimation method forestimating the joining strength.

FIG. 11 is a plan view showing an estimation result for illustrating theestimation method for the joined object, this method being a secondembodiment of the present invention.

FIG. 12 is a graph for showing distribution of the joining strength ofthe joined object 20 measured by the destructive inspection, relative toan area of the estimated joined region 21.

FIG. 13 is a graph for showing a result of a frequency analysis of awave form included in an observed reflected wave 45.

FIG. 14 is a block diagram showing an estimation apparatus 130 of athird embodiment of the present invention.

FIG. 15 is a diagram for illustrating changes of a peak frequency,relative to the changes of the scanning position.

FIG. 16 is a diagram for illustrating changes of a bandwidth, relativeto the changes of the scanning position.

FIG. 17 is a graph for illustrating the estimation method of a fourthembodiment of the present invention.

FIG. 18 is a perspective view showing one example of the ultrasonicprobe 31 used in the first to fourth embodiments.

FIG. 19 is a perspective view showing an ultrasonic probe 200 related toa fifth embodiment of the present invention.

FIG. 20 is a diagram showing a relationship between the scanningposition and the echo level.

FIG. 21 is a graph showing a relationship between a relative echo leveland the area of the joined region 21.

FIG. 22 is a diagram for illustrating a measuring method employing theultrasonic probe 300, this method being one modification for eachembodiment.

FIG. 23 is a diagram for illustrating a measuring method employing anultrasonic probe 400, this method being a sixth embodiment of thepresent invention.

FIG. 24 is a graph showing a relationship between a joined regiondiameter and the echo level, in the measuring method according to thesixth embodiment of the present invention.

FIG. 25 is a diagram for illustrating the estimation method forestimating the welded region 2 of the welded object 1 welded by theresistance spot welding of the conventional art.

BEST MODE FOR CARRYING OUT THE INVENTION

An estimation method for a joined region of a joined object, accordingto a first embodiment of the present invention, is used for estimatingthe joined region 21 of the joined object 20 shown in FIG. 1. In thisembodiment, the joined object 20 is formed by joining two members 22, 23together along the reference directions Z, by utilizing the frictionstir joining method, these two members 22, 23 having been put one onanother in advance along the reference directions Z.

In the spot friction stir joining method, a joining tool is pressed intoa tool plunging face 24 that is a surface located in one referencedirection Z1 of the joining member 23 located in the one referencedirection Z1 of the two joining members 22, 23 while the joining tool isrotated. Consequently, frictional heat is generated between the joiningtool and the one joining member 23 so as to soften the one joiningmember 23. Thus, a distal end of the joining tool is pressed into andplunged through the one joining member 23 until it reaches the otherjoining member 22. At this time, softened portions of the respectivejoining members 22, 23 are plastically flowed about a rotation axis withthe joining tool. After the respective softened portions of the joiningmembers 22, 23 are plastically flowed, the joining tool is withdrawnfrom the joining members 22, 23 in the one reference direction Z1.

The joining tool is designed to include a generally cylindrical pinportion and a generally cylindrical shoulder portion connected with oneend of the pin portion and formed coaxially with the pin portion. Thediameter of the shoulder portion is formed to be larger as compared withthe diameter of the pin portion. The joining tool is configured to beplunged into the tool plunging face 24 of the one joining member 23 fromits pin portion as a distal portion. In a state in which the pin portionextends through the one joining member 23 and is plunged in the otherjoining member 22, the shoulder portion is also plunged in the onejoining member 23 and is pressed against the other joining member 23.

Due to such plastic flowing of interfacial portions of the respectivejoining members 22, 23, the two joining members 22, 23 will be mixedtogether by friction stirring in the vicinity of an interface thereof.As a result, the interface 27 between the two joining members 22, 23will disappear, and hence the two joining members 22, 23 aremetallurgically integrated. Thus, a portion, in which the interfacebetween the two joining members 22, 23 has disappeared, will be referredto as the joined region 21 of the two joining members 22, 23.

The joined object 20 after the joining process is formed to include astirred portion 21 a and a heat-influenced portion 21 b. The stirredportion 21 a corresponds to a portion which was rotated with the pinportion and plastically flowed upon the friction stirring. Namely, thestirred portion 21 a corresponds to the portion which was adjacent to orfacing the pin portion of the joining tool upon the friction stirring,and is formed into a substantially ring-like shape, coaxially with theaxis of a joining mark 29. In addition, the stirred portion 21 a has astructure in which metal crystal grains of a metallographic structureare formed more finely as compared with the remaining portion. Theheat-influenced portion 21 b corresponds to a portion which was formedinto a substantially ring-like shape covering the stirred portion 21 a.Namely, the heat influenced portion 21 b corresponds to the portionwhich was softened upon the friction stirring due to heat applied fromthe stirred portion 21 a and the joining tool.

In the joined object 20, the joined region 21, which contributes to thejoining strength, is formed. The joining region 21 is configured toinclude a stir-joined region 21 c and a pressure-joined region 21 d. Thestir-joined region 21 c corresponds to a part of the stirred portion 21a, which has disappeared as a melted mixture of the interfacial portionsbetween the upper plate 22 and the lower plate 23, the melted mixturebeing mainly caused by stirring due to plastic flowing. Thepressure-joined region 21 d corresponds to a part of the heat-influencedportion 21 b. The pressure-joined region 21 d has been formed in theportion where the interfacial portions between the upper plate 22 andthe lower plate 23 disappeared mainly due to the influence of thesoftening of each plate 22, 23 by the frictional heat and the pressingby the shoulder portion of the joining tool. The stir-joined region 21 cand the pressure-joined region 21 d are formed in a position, in whichthe interface between the respective plates 22, 23 has existed beforethe joining process, and have a ring-like shape coaxial with the axis ofthe joining mark 29, respectively. The size of such a joined region 21will have a substantial effect on the joining strength of the joinedobject 20.

In the joined object 20 after the joining process, the joining mark 29of the joining tool remains as the concave/convex shape formed in thesurface on the side of the one reference direction Z1 of the joiningmember 23 located in the one reference direction Z1. The joining mark 29is a generally concave cylindrical portion which opens in one directionand has a bottom portion. In the joined object 20, a backing face 25opposed to the tool plunging face 24 is maintained as a flat face.Hereinafter, the joining member 22 located in the other referencedirection Z2 will also be referred to as the upper plate 22, and thejoining member 23 located in the one reference direction Z1 will also bereferred to as the lower plate 23. In addition, a region other than thejoined region 21 will be referred to as a non-joined region 28. In thenon-joined region 28, the upper plate 22 and the lower plate 23 are notjoined together, and the interface 27 exists between the upper plate 22and the lower plate 23.

As shown in FIG. 1, in this embodiment, by using the ultrasonic probe31, an ultrasonic wave is radiated or introduced into the joined object20 from the backing face 25 of the joined object 20 opposed to the toolplunging face 24 thereof in which the joining tool was plunged upon thefriction stir process, while a reflected wave of the ultrasonic waveintroduced in the joined object 20 is taken in. The ultrasonic wavegenerated by the ultrasonic probe 31 is scanned such that each positionin which the ultrasonic wave is introduced is located along apredetermined scanning direction X and such that the ultrasonic wavepasses through over the joined region 21 of the joined object 20.

In the estimation method of this embodiment, the joined region 21 isestimated based on changing amounts of amplitude of an observedreflected wave reflected in the vicinity of a position corresponding tothe interface 27 of the two joining members 22, 23, among the reflectedwaves taken in due to the ultrasonic probe 31. Hereinafter, theamplitude of the observed reflected wave will be referred to as an echolevel. Namely, the echo level is the maximum amplitude of the observedreflected wave and corresponds to the intensity of the observedreflected wave. In this embodiment, a scanning position measured whenthe echo level becomes lower than a predetermined threshold value isestimated as a position over the joined region 21.

FIG. 2 is a block diagram showing the estimation apparatus 30 forestimating the joined region 21. In this embodiment, the estimationapparatus 30 is also configured to estimate the joining strength, whichis also referred to as joint strength, of the joined object 20. In thisembodiment, the joining strength of the joined object 20 is regarded asstrength measured when pulling force is applied to rip off the upperplate 22 from the lower plate 23 in the reference directions Z or asstrength measured when shearing force is applied to the upper plate 22and lower plate 23 in a direction vertical to the reference directionsZ.

The estimation apparatus 30 is configured to include the ultrasonicprobe 31, a probe moving means 32, a scanning position detection means33, an ultrasonic transmitter/receiver 34, and a computer 35. Theultrasonic probe 31 is configured to include an electric sound converterelement, which is adapted to generate an ultrasonic wave when vibrateddue to application thereto of a pulsed electric signal from theultrasonic transmitter and receiver 34. In addition, the ultrasonicprobe 31 is configured to be vibrated when receiving an ultrasonic wave,so as to generate a pulsed electric signal corresponding to thevibration, thus providing the generated electric signal to theultrasonic transmitter and receiver 34. The ultrasonic probe 31 is alsoconfigured such that it can introduce the ultrasonic wave into thejoined object 20 as well as it can take therein the reflected wavereflected from the interior of the joined object 20.

In this embodiment, the ultrasonic probe 31 is a single probe which cantransmit and receive the ultrasonic wave, having a beam diameter of0.8×0.5 mm and is adapted to generate the ultrasonic wave having afrequency of 17 MHz. Between the ultrasonic probe 31 and the joinedobject 20, a contact medium is placed for transmitting and receiving theultrasonic wave. For instance, the contact medium is a water bag filledwith water, a liquid like water, or a jerry-like material such asglycerin or the like.

The probe moving means 32 is configured to displace the ultrasonic probe31. In this embodiment, the probe moving means 32 scans the ultrasonicprobe 31 over the backing face 25 of the joined object 20, such that theultrasonic probe 31 can pass through over the joined region 21 of thejoined object 20. Specifically, the probe moving means 32 is configuredto drive and displace the ultrasonic probe 31 in a first directionvertical to the reference directions Z as well as in a second directionvertical to both of the reference directions Z and the first direction.More specifically, the probe moving means 32 scans the ultrasonic probe31, while keeping an incident direction of the ultrasonic wave verticalto the backing face 25. The scanning position detection means 33 isconfigured to detect a scanning position of the ultrasonic probe 31. Thescanning position detection means 33 provides a scanning position signalindicative of the scanning position of the ultrasonic probe 31 to thecomputer 35.

The ultrasonic transmitter and receiver 34 provides the pulsed electricsignal to the ultrasonic probe 31 so as to vibrate the ultrasonic probe31. Besides, the ultrasonic transmitter and receiver 34 is configured toamplify the pulsed electric signal provided from the ultrasonic probe 31and corresponding to the reflected wave, convert the electric signalinto a reflected wave signal indicative of the reflected wave taken inthe ultrasonic probe 31, and provide the reflected wave signal to thecomputer 35. The reflected wave signal is indicative of changes overtime of the amplitude of the ultrasonic wave taken in the ultrasonicprobe 31.

The computer 35 is configured to include an observed reflected waveextraction unit 42, an echo level measuring unit 36, a joined regionestimation unit 37, a joining strength estimation unit 38, a memory orstorage means 39, an input unit 41, and a display 40. The observedreflected wave extraction unit 42 is configured to extract the observedreflected wave reflected in the vicinity of a position corresponding tothe interface between the two joining members, based on the reflectedwave signal provided from the ultrasonic transmitter and receiver 34,for each displacement of the scanning position of the ultrasonic probe31. The echo level measuring unit 36 is configured to measure the echolevel that is the amplitude of the observed reflected wave, based on theresult of extraction due to the observed reflected wave extraction unit42, for each displacement of the scanning position of the ultrasonicprobe 31, and send the measured echo level to the memory 39 in order tostore it therein.

The memory 39 receives a scanning position signal from the scanningposition detection means 33. The memory 39 is configured to storetherein the scanning position of the ultrasonic probe 31 detected by thescanning position detection means 33, in relation to the echo levelmeasured by the echo level measuring unit 36, corresponding to thescanning position. The joined region estimation unit 37 is configured toread information stored in the memory 39 and estimate the scanningposition that satisfies a predetermined boundary condition, as aposition located over the joined region 21. The joining strengthestimation unit 38 is configured to estimate the size of the joinedregion 21, based on the position over the joined region 21 estimated bythe joined region estimation unit 37, and further estimate the joiningstrength, based on a one-to-one relationship with the estimated size.

The display 40 is configured to display information indicative of theecho level stored in the memory 39 and the scanning position storedtherein in relation to the echo level. The display 40 also displays thejoining strength estimated by the joining strength estimation unit 38.The input unit 41 is configured such that the predetermined boundarycondition required for estimation of the joined region 21 is introducedthereto as well as configured to provide the introduced boundarycondition to the joined region estimation unit 37. Additionally, theinput unit 41 is configured such that the information indicative of therelationship, between the size of the joined region 21 and the joiningstrength, necessary for estimation of the joining strength, isintroduced thereto as well as configured to provide the introducedrelational information to the joining strength estimation unit 38. Inthis embodiment, the echo level extraction unit 36, joined regionestimation unit 37 and joining strength estimation unit 38 can beachieved by performing operating programs stored in a preset memorycircuit by using a processor circuit 43, such as a central processingunit (CPU).

FIG. 3 is a diagram showing a transfer route of the ultrasonic probe 31moved by the probe moving means 32. As shown in FIG. 3(1), the probemoving means 32 causes the ultrasonic probe 31 to move in the scanningdirection vertical to the reference directions Z such that it can passthrough over a central position 43 of the joining mark 29. Specifically,the probe moving means 32 moves the ultrasonic probe 31 in one scanningdirection, from a position sufficiently far away from the joined region21 on one side along the scanning direction to a position sufficientlyfar away from the joined region 21 on the other side along the scanningdirection. In other words, the probe moving means 32 moves theultrasonic probe 31 from a position over one non-joined region 28adjacent to the joined region 21 on one side along one scanningdirection, such that the ultrasonic probe 31 passes through over thejoined region 21 in the scanning direction and then reaches the othernon-joined region 28 adjacent to the joined region 21 on the other sidealong the scanning direction. It is noted that each non-joined region 28is a region including the interface 27 present between the two joiningmembers 22, 23.

Alternatively, as shown in FIG. 3(2), the ultrasonic probe 31 may bemoved both in a first scanning direction X and in a second scanningdirection Y. The first and second directions X, Y are respectivelydefined to pass through over the central position 43 of the joining mark29 and extend vertically to the reference directions Z and orthogonallyto each other. Also in this case, the ultrasonic probe 31 is scanned topass through over the joined region 21 along the backing face 25 in bothof the first and second directions.

Alternatively, as shown in FIG. 3(3), the ultrasonic probe 31 may bemoved along the backing face 25 so as to be scanned over the wholetwo-dimensional surface area set in advance to include a regionspreading over the joined region 21. For instance, the ultrasonic probe31 may be first moved in a main scanning direction vertical to thereference directions Z, then shifted in a sub-scanning directionvertical to the main scanning direction, and thereafter moved again inthe main scanning direction. Furthermore, by repeating such operations,the ultrasonic probe 31 may be scanned over the preset wholetwo-dimensional surface area.

FIG. 4 is a diagram showing a wave form of an ultrasonic reflected wavereflected from the joined object 20. In FIG. 4, time is expressed on thehorizontal axis, while the amplitude is designated on the vertical axis.When the scanning position is located over the non-joined region 28, thereflected wave will include a reflected wave 44 reflected at the backingface 25 that is a top face of the upper plate 22 and the reflected wave45 reflected at the interface 27 between the upper plate 22 and thelower plate 23.

The observed reflected wave extraction unit 42 obtains a reference timeT1 defined between the time the reflected wave 44 reflected from the topface 25 of the upper plate 22 reaches the ultrasonic probe 31 and thetime the reflected wave 45 reflected from the interface 27 between theupper plate 22 and the lower plate 23 reaches the ultrasonic probe 31,base on the reflected wave signal provided from the ultrasonictransmitter/receiver 34. In addition, the observed reflected waveextraction unit 42 sets a gate interval W defined across the referencetime T1. Specifically, the gate interval W is set as a time intervaldefined from the time (T1−A1) set earlier than the reference time T1 tothe time (T1+A2) set later than the reference time T1. The observedreflected wave extraction unit 42 is configured to extract eachreflected wave taken in the ultrasonic probe 31 during the gate intervalW, as the observed reflected wave 45 reflected in the vicinity of aposition, in the reference directions Z, corresponding to the interface27 between the two joining members 22, 23. Then, the echo levelmeasuring unit 36 outputs the amplitude that is the highest of theobserved reflected waves extracted over the gate interval W, as the echolevel.

FIG. 5 is a diagram for illustrating changes of the wave form of thereflected wave, relative to changes of the scanning position. FIG. 5(1)illustrates the wave form of the reflected wave when the scanningposition is over the non-joined region 28. FIG. 5(2) illustrates thewave form of the reflected wave when the scanning position is over thejoined region 21.

In the non-joined region 28, since the interface 27 exists between theupper plate 22 and the lower plate 23, the ultrasonic wave introducedfrom the upper plate 22 is reflected from the interface 27 between theupper plate 22 and the lower plate 23. Contrary, in the joined region21, since the interface 27 between the upper plate 22 and the lowerplate 23 has disappeared, the reflected wave introduced from the upperplate 22 is transmitted through the lower plate 23 without beingreflected in the upper plate 22.

Accordingly, as shown in FIG. 5(1), when the scanning position islocated over the non-joined region 28, the reflected wave reflected fromthe interface 27 between the upper plate 22 and the lower plate 23 isrelatively great, rendering the echo level of the observed reflectedwave 45 significantly higher. Contrary, as shown in FIG. 5(2), when thescanning position is over the joined region 21, the reflected wavereflected from a position in the reference directions corresponding tothe interface 27 between the upper plate 22 and the lower plate 27 issubstantially reduced, thus lowering the echo level of the observedreflected wave 45.

FIG. 6 is a diagram for illustrating changes of the echo level, relativeto the changes of the scanning position. FIG. 6(1) illustrates thechanges of the echo level, relative to the changes of the scanningposition, and FIG. 6(2) is a section of the joined object 20corresponding to the graph of FIG. 6(1). In FIG. 6(1), the scanningposition is expressed on the horizontal axis, while the echo level isdesignated on the vertical axis. More specifically, in FIG. 6(1), apercentage of the echo level for each scanning position relative to areference echo level H0 is expressed on the vertical axis. The referenceecho level H0 corresponds to the echo level when the scanning positionis located over the non-joined region 28.

As shown in FIG. 3(1), when the ultrasonic probe 31 is scanned in thescanning direction such that it can pass through the center of thejoining mark 29, the scanning position, in which the echo level measuredfor each scanning position is lower than a preset level threshold valueC1, can be estimated as a position over the joined region 21, as shownin FIG. 6(1).

In addition, a scanning position P1 in which the echo level for eachscanning position is switched from a state higher than the levelthreshold value C1 to a state lower than the same threshold value and ascanning position P2 in which the echo level is switched from the statelower than the level threshold value C1 to the state higher than thesame threshold value can be estimated as positions over the boundarybetween the joined region 21 and the non-joined region 28, respectively.Furthermore, the length of a line connecting the two scanning positionsP1, P2 over the respective boundary positions can be estimated as adiametric size of the joined region 21.

The level threshold value C1 that is the boundary condition for judgingwhether or not the scanning position is located over the joined region21 is determined, based on the observed reflected wave when theultrasonic wave incident position is located over the non-joined region28. Namely, the level threshold value C1 is set lower than the echolevel measured when the ultrasonic wave incident position is locatedover the non-joined region 28. For instance, the level threshold valueC1 is determined based on a function of variables including a platethickness t1 of the upper plate 22, a plate thickness t2 of the lowerplate 23, a factor L1 related to joining conditions, a factor L2 relatedto the tool shape, and a factor L3 related to materials (i.e., C1=f (t1,t2, L1, L2, L3). In other words, the level threshold value C1 is setlower than the reference echo level H0 and defined as the echo levelmeasured when the scanning position is located over the boundary betweenthe joined region 21 and the non-joined region 28. In this embodiment,the level threshold value C1 is determined based on a function ofvariables including the plate thickness t1 of the upper plate 22 and thereference echo level H0. In this case, the level threshold value C1 isset at a level obtained by lowering the reference echo level H0 by −α−20Log(t2 ^(1/2)) decibels. As described above, the factor t2 is the platethickness of the lower plate 23. Again, the reference echo level H0 isset as an echo level when the scanning position is located over thenon-joined region 28. The variable α is a constant, and in thisembodiment, α=9.

Alternatively, when the reference echo level is expressed as H0, thelevel threshold value C1 may be set as H0×β. In this case, β is aconstant, and in this embodiment, it is set at, for example, 0.35. It isnoted that the variables α, β may be optionally altered depending on thejoining materials, joining conditions, shape of the joining tool and thelike and may be experimentally determined in advance prior to theestimation.

FIG. 7 and FIG. 8 are graphs for respectively showing a comparison ofdistribution of a diametric size of the estimated joined region 21(solid line) with the diametric size of the joined region 21 obtained byobservation of a ruptured face thereof after estimation. In each ofFIGS. 7 and 8, the diametric size of the joined region 21 obtained byobservation of the ruptured face is expressed on the horizontal axis,while the estimated joined region 21 is designated on the vertical axis.FIG. 7 shows a case in which the plate thickness of each plate 22, 23 is1 mm, while FIG. 8 shows a case in which the plate thickness of eachplate 22, 23 is 2 mm. As shown in FIGS. 7 and 8, it is found that theobservation result obtained from the ruptured face has correlativelywith the estimation result. Accordingly, with the estimation method asdescribed above, the diametric size L of the joined region 21 can beestimated without destroying the joined object 20.

FIG. 9 is a graph for showing distribution of the joining strength ofthe joined object measured by a destructive inspection, relative to thediametric size of the estimated joined region 21. In this case, thejoining strength that is estimated based on each average value of thediametric size of the estimated joined region is shown by a solid line,while the joining strength that is estimated based on each valueobtained by changing ±20% the average value of the estimated diametricsize of the joined region is shown by broken lines, respectively. Asshown in FIG. 9, there is a one-to-one mutual relation between theestimated diametric size L of the joined region 21 and the joiningstrength. Accordingly, with preparation of a computing equation or database expressing the relationship between the previously estimateddiametric size L of the joined region 21 and the joining strength, thejoining strength can be calculated, in accordance with such a computingequation or data base, from the estimated joined region 21. Forinstance, when the estimated diametric size of the joined region 21 isexpressed as L, the joining strength will be generally expressed byK1·L². In this case, K1 is a predetermined constant, which can beexperimentally obtained.

FIG. 10 is a flow chart showing a procedure of the estimation method ofestimating the joining strength. First, in a step a0, the joined objecthaving been subjected to the spot friction stir joining process isprepared and the estimation apparatus 30 is also prepared. In addition,a relational expression for obtaining the level threshold value C1 isexperimentally obtained from the reference echo level, while therelational expression for estimating the joining strength isexperimentally obtained from the diametric size L of the estimatedjoined region 21. Besides, whether or not the joining strength should beestimated is determined. Once such preparations required for theestimation work for the joined object has been completed, the proceduregoes to a step a1, in which the estimation work is started.

In the step a1, a reflected wave measuring step is performed, in whichthe reflected wave generated when the ultrasonic wave is introduced intothe joined object 20 by the ultrasonic probe 31 is measured. Then, thereflected wave is taken in the ultrasonic probe 31 while the ultrasonicprobe 31 is scanned by the probe moving means 32. In this way, once thereflected wave has been measured for each scanning position with theultrasonic probe 31 being scanned, the procedure goes to a step a2.

In the step a2, the observed reflected wave is extracted for eachpredetermined microscopic scanning position, from the reflected waves,by using the observed reflected wave extraction unit 42. Subsequently,by using the echo level measuring unit 36, the echo level of theobserved reflected wave extracted for each scanning position ismeasured. Optionally, the observed reflected wave extraction unit 42 maydetermine the gate interval W for capturing the observed reflected wave,based on the plate thickness of the upper plate 22 introduced from theinput unit 41. In this manner, once the step of measuring the echo levelfor each scanning position has been completed, the procedure goes to astep a3.

In the step a3, the reference echo level H0 when the scanning positionis located over the non-joined region 28 is determined, among the echolevels for each scanning position obtained in the step a2, by using thejoined region estimation unit 37. For example, the reference echo levelH0 is obtained as an average of the echo levels obtained during thescanning operation over the non-joined region 28. Once the joined regionestimation unit 37 has determined the reference echo level H0, theprocedure goes to a step a4.

In the step a4, the joined region estimation unit 37 determines thelevel threshold value C1 based on the function of the variables, i.e.,the reference echo level H0 and the plate thickness t1 of the upperplate 22. Once the level threshold value C1 has been determined, the twoscanning position P1, P2 that correspond to the echo level coincidentwith the level threshold value C1 are extracted, respectively.Thereafter, the length of the line connecting the two scanning positionsP1, P2 is estimated as the diametric size L of the joined region 21, andthen the procedure goes to a step a5.

In the step a5, if the estimation of the joining strength is determinedto be performed, the procedure goes to a step a6, while if it is notdetermined to be performed, the procedure goes to a step a7. Forinstance, in the case of estimating the joining strength, a joiningstrength estimation command is introduced, in advance, due to the inputunit 41. Then, when the processor circuit 43 judges that the strengthestimation command has been introduced, the procedure goes to the stepa6, while if not so, the procedure goes to the step a7.

In the step a6, the joining strength estimation unit 38 estimates thejoining strength, based on the diametric size L of the estimated joinedregion 21 as well as on the relational expression or data base forobtaining the joining strength provided in advance. As shown in FIG. 9,since the diametric size L of the estimated joined region 21 and thejoining strength have a one-to-one relationship relative to each other,the joining strength can be estimated, based on the relationship,without destroying the joined object 20. In such a manner, once thejoining strength has been estimated, the estimation result is displayedon the display 40, and then the procedure goes to a step a7. In the stepa7, the estimation operation for the joining strength is ended. In thisembodiment, although the estimation procedure includes the step ofestimating the joining strength, the estimation work may be ended whenthe step of estimating the diametric size L of the joined region 21 isended, without estimating the joining strength. Alternatively, theestimation result obtained by the joined region estimation unit 37 maybe displayed on the display 40.

As described above, according to this embodiment, the joined region 21can be estimated, based on the observed reflected wave of the ultrasonicwave, by introducing the ultrasonic wave into the joined object 20 fromthe backing face 25 opposed to the joining tool plunging face 24.Consequently, the joined region 21 and the joining strength can bereliably estimated, without being affected by the unevenness orconcave/convex shape formed in the joining tool plunging face 24, thatis, even in the case in which the thickness of the joined object 20 ischanged by the joining mark 29.

In this manner, by estimating the joined region 21 by using theultrasonic wave, the quality of joining and the joining strength can beestimated, without destroying the joined object 20, as suchsignificantly reducing the cost required for the quality inspection ascompared with the case requiring the destructive inspection. Besides,even in the case of a large-size joined object for which the destructiveinspection is usually difficult, the joining quality and the joiningstrength can be estimated.

For instance, in the case in which the time required for plunging thejoining tool is relatively short, or the like case, the size of thejoined region 21 is not consistent even under the same joiningconditions, causing variation in the joining strength. Even in such acase, according to this embodiment, the joining strength can beestimated by using the ultrasonic wave, without destroying the joinedobject 20. Accordingly, the time and labor required for preparing thejoined object for use in the destructive inspection and the time andlabor for performing the destructive inspection can be saved, therebyenhancing the working efficiency. Additionally, even after producingproducts each including the joined object 20, the quality inspection forestimating the joining strength of the joined object 20 can beperformed, without destroying each product.

Furthermore, according to this embodiment, by scanning the ultrasonicprobe 31, each position over the boundary of the joined region 21 andthe non-joined region 28 can be estimated as well as a general size ofthe joined region 21 can be estimated. Thus, information necessary forworks for obtaining the joining strength as well as for inspecting thequality of joining can be obtained.

Moreover, the level threshold value C1 as the boundary condition can bedetermined based on the observed reflected wave in the case in which theultrasonic wave incident position is located over the non-joined region28. Consequently, the boundary condition can be determined for eachjoined object 20. Thus, even in the case in which the boundary conditionvaries with each joined object 20, the joined region 21 can be preciselyestimated. In addition, since the joined region 21 is estimated based onthe echo level, i.e., the amplitude of the observed reflected wave,there is no need for analyzing frequencies of wave forms included in thereflected wave, significantly facilitating the estimation for the joinedregion 21. Besides, since the reference echo level can be obtained whenthe ultrasonic probe is scanned over the non-joined region 28, theworking accuracy and efficiency can be enhanced.

While, in this embodiment, the joined region 21 is estimated based onthe echo level of the observed reflected wave, the estimation is notlimited to this aspect. For instance, the joined region 21 may also beestimated from the scanning position when another feature than the echolevel of the observed reflected wave satisfies the predeterminedboundary condition. For example, as in a third embodiment describedbelow, the joined region 21 may be estimated based on a feature relatedto the frequency of the observed reflected wave.

While, in the embodiment described above, the estimation method and theestimation apparatus for estimating the joined region 21 and the joiningstrength of the joined object have been shown and discussed, a testingmethod employing such an estimation method is also included in thepresent invention. Namely, this testing method is designed to inspectthe joined object based on the estimation result obtained by theestimation method. For example, in the case in which the size of theestimated joined region 21 or joining strength is greater than apredetermined acceptable value, the object can be inspected or judged asone satisfying the required joining quality. In this manner, byinspecting each joined object by using the aforementioned estimationmethod, the joined object can be inspected in a non-destructive manner,thereby enhancing the working efficiency. For example, the so-called onehundred percent inspection can be performed for the joined objects, assuch correctly eliminating incompletely joined products.

Furthermore, a testing apparatus adapted to inspect the joined objectdescribed above is also included in the present invention. In additionto the construction of the estimation apparatus shown in FIG. 2, thetesting apparatus further includes a judging unit or judging meansadapted for judging whether each joined object is acceptable or not.Namely, the judging unit is adapted to judge whether or not theestimation result obtained due to the estimation means satisfies apredetermined required value. For example, if the size of the joinedregion 21 or joining strength is judged to be greater than the requiredvalue, the quality of the inspected joined object will be judged tosatisfy a predetermined quality. In this case, this judgment result isdisplayed on the display 40. The judging unit can be achieved byperforming operating programs stored in a preset memory circuit, byusing the processor circuit 43. The judging unit is configured tocompare an introduced acceptable value with an estimated value when anacceptable diameter, acceptable area or acceptable strength of thejoined region 21 is introduced as the introduced value by the inputunit.

FIG. 11 is a plan view showing an estimation result for illustrating theestimation method for the joined object, this method being a secondembodiment of the present invention. While the diametric size L has beenestimated as the size of the joined region 21 in the first embodiment ofthis invention, the area is used for estimating the size of the joinedregion 21 in the second embodiment of this invention. Because the otherconstruction is the same as that of the first embodiment, the sameconstruction will not be detailed below, and like parts will bedesignated by like reference numerals.

As shown in FIG. 3(2), when the ultrasonic probe 31 is scanned in bothof the first scanning direction X and the second scanning direction Y,the joined region estimation unit 37 obtains a diametric size Lx of thejoined region 21 estimated in the case in which the ultrasonic probe 31is scanned in the first scanning direction X and a diametric size Ly ofthe joined region 21 estimated in the case in which the ultrasonic probe31 is scanned in the second scanning direction Y, respectively.Thereafter, the joined region estimation unit 37 estimates the area ofthe joined region 21 as a value obtained by Lx·Ly·π/4, in which Lx isthe diametric size of the joined region 21 in the first scanningdirection X and Ly is the diametric size of the joined region 21 in thesecond scanning direction Y.

Alternatively, as shown in FIG. 3(3), when the ultrasonic probe 31 isscanned over the preset whole two-dimensional surface area including theregion spreading over the joined region 21, the joined region estimationunit 37 estimates the area of the joined region 21 as an area obtainedby totaling respective regions corresponding to scanning positions eachexhibiting the echo level lower than the level threshold value C1. InFIG. 11, regions depicted white correspond to the scanning positionseach exhibiting the echo level lower than the level threshold value C1.Thus, the area of the joined region 21 can be estimated as an areaobtained by totaling the respective regions depicted white.

FIG. 12 is a graph for showing distribution of the joining strength ofthe joined object 20 measured by the destructive inspection relative tothe area of the estimated joined region 21. In FIG. 12, the joiningstrength estimated based on an average of the estimated area of thejoined region is expressed by a solid line, while the joining strengthestimated based on each value obtained by changing ±20% the averagevalue of the estimated area of the joined region is shown by brokenlines, respectively. As shown in FIG. 12, it is found that there is aone-to-one mutual relation between the estimated area of the joinedregion 21 and the joining strength. Accordingly, with preparation of acomputing equation or data base expressing the relationship between thearea of the joined region 21 estimated in advance and the joiningstrength, the joining strength can be calculated, by using such acomputing equation or data base, based on the estimated joined region21. For instance, when the estimated area of the joined region 21 isexpressed as A, the joining strength will be generally expressed byK2·A. In this case, K2 is a predetermined constant, which can beexperimentally obtained.

In such a manner, also in the case of obtaining the area as the size ofthe joined region 21, the joining strength can be obtained by using theprocedure of the estimation method similar to that shown in FIG. 10. Inthis case, as compared with the case shown in FIG. 10, in the step a4 ofestimating the size of the joined region 21, the area of the joinedregion 21 will be estimated. In addition, in the step a5 of estimatingthe joining strength, the joining strength estimation unit 38 willestimate the joining strength, based on the estimated area A of thejoined region 21 as well as on the preset computing equation or database for obtaining the joining strength. Because the other steps aresimilar to those in the procedure shown in FIG. 10, they are notdetailed now. In this embodiment, by obtaining the joining strengthbased on the area of the joined region 21, rather than on the diametricsize of the joined region 21, the joining strength can be more preciselyestimated, even in the case in which the joined region 21 is formed intoa generally elliptic shape.

FIG. 13 is a graph for showing a result of a frequency analysis of awave form included in the observed reflected wave 45. In this case, thehorizontal axis designates frequency distribution of the wave formincluded in the observed reflected wave. The vertical axis expresses theamplitude for each frequency of the wave form included in the observedreflected wave. Also in FIG. 13, the frequency distribution of the waveform included in the observed reflected wave when the scanning positionis located over the non-joined region 28 is shown by a broken line. Inaddition, the frequency distribution of the wave form included in theobserved reflected wave when the scanning position is located over thejoined region 21 is shown by a solid line.

When the scanning position is located over the joined region 21, ascompared with the case in which it is located over the non-joined region28, since the interface 27 between the upper plate 22 and the lowerplate 23 has disappeared, the ultrasonic wave is more likely to betransmitted from the upper plate 22 to the lower plate 23. Of the waveforms included in the reflected wave, the wave forms in a higherfrequency band exhibit higher directivity as compared with the waveforms in a lower frequency band. If the boundary face between the joinedregion 21 and each of the remaining regions is inclined relative to thebacking face 25, the wave forms in the higher frequency band will betaken in, in a lesser amount, as the reflected wave. Besides, the waveforms in the higher frequency band are more likely to be lowered ascompared with those in the lower frequency band.

Accordingly, with respect to a peak frequency fp, a frequency of thewave form exhibiting the maximum amplitude value in the frequencydistribution band of the wave form included in the observed reflectedwave, a peak frequency fp1 when the scanning position is located overthe joined region 21 is lower than a peak frequency fp0 when thescanning position is located over the non-joined region 28. With respectto a central frequency fc, a frequency positioned at the center of thefrequency distribution band lower by a predetermined amount than themaximum frequency value in the frequency distribution band of the waveform included in the observed reflected wave, a central frequency fc1when the scanning position is located over the joined region 21 is lowerthan a central frequency fc0 when the scanning position is located overthe non-joined region 28. In this embodiment, the amplitude value lowerby the predetermined amount than the maximum amplitude value is setlower by a predetermined rate, for example 6 dB, as compared with theamplitude value of the wave form of the peak frequency fp.

In addition, with respect to an observed frequency bandwidth B of a waveform higher than an amplitude value lower by a predetermined amount thanthe maximum amplitude value in the frequency distribution band of thewave form included in the observed reflected wave, an observed frequencybandwidth B1 when the scanning position is located over the joinedregion 21 is greater than an observed frequency bandwidth B0 when thescanning position is located over the non-joined region 28. In thisembodiment, the amplitude value lower by the predetermined amount thanthe maximum amplitude value is set lower by a predetermined rate, forexample 6 dB, as compared with the amplitude value of the wave form ofthe peak frequency fp.

FIG. 14 is a block diagram showing the estimation apparatus 130 of thethird embodiment of the present invention. The estimation apparatus 130of the third embodiment of this invention has a construction similar tothat of the estimation apparatus 30 of the first embodiment. Thus, thesame construction as in the first embodiment will not be detailed below,and like parts will be designated by like reference numerals.

The estimation apparatus 130 of the third embodiment includes afrequency feature measuring unit 101 provided in place of the echo levelmeasuring unit 36 of the estimation apparatus 30 of the firstembodiment. In addition, the estimation apparatus 130 further includes afrequency conversion unit 100. The frequency conversion unit 100 isconfigured to analyze the frequency of the wave form included in theobserved reflected wave extracted by the observed wave form extractionunit 42 and separate the wave form included in the observed reflectedwave into each frequency component. The frequency conversion unit 100provides the result of frequency analysis to the frequency featuremeasuring unit 101. The frequency feature measuring unit 101 isconfigured to measure an amount of a feature required for estimating thejoined region 21, for each scanning position of the ultrasonic probe 31,from the result of frequency analysis and then provide the result ofmeasurement, in succession, to the memory 39 in order to store ittherein. The frequency conversion unit 100 and frequency featuremeasuring unit 101 can be achieved by performing operating programsstored in a preset memory circuit by employing a processor circuit 43.Consequently, the joined region estimation unit 37 reads the informationstored in the memory 39 by the frequency feature measuring unit 101 andestimates the scanning position corresponding to the frequency featuresatisfying the predetermined boundary condition, as a position over thejoined region 21. The other construction is similar to that of theestimation apparatus 30 of the first embodiment shown in FIG. 2.

FIG. 15 is a diagram for illustrating changes of the peak frequencyrelative to the changes of the scanning position. FIG. 15(1) is a graphillustrating the changes of the peak frequency relative to the changesof the scanning position, and FIG. 15(2) is a section of the joinedobject corresponding to the graph of FIG. 15(1). In FIG. 15(1), thescanning position is expressed on the horizontal axis, while the peakfrequency is designated on the vertical axis. In the case in which theultrasonic probe 31 is scanned in the scanning direction such that itcan pass through the center of the joining mark 29 as shown in FIG.3(1), the scanning position, in which the peak frequency fp of eachscanning position is lower than a preset peak frequency threshold valueC2, can be estimated as a position over the joined region 21, as shownin FIG. 15(1). The peak frequency threshold value C2 is used as areference of the boundary condition for judging whether or not thescanning position is located over the joining region 21, and is setlower than the peak frequency fp0 of the observed reflected wave in thecase in which the ultrasonic wave incident position is located over thenon-joined region 28.

In addition, the scanning position P1 in which the peak frequency fp ofeach scanning position is switched from a state higher than the peakfrequency threshold value C2 to a state lower than the same thresholdvalue C2 and the scanning position P2 in which the peak frequency isswitched from the state lower than the peak frequency threshold value C2to the state higher than the same threshold value C2 can be estimated aspositions over the boundary between the joined region 21 and thenon-joined region 28, respectively. Furthermore, the length of the lineconnecting the two scanning positions P1, P2 over the respectiveboundary positions can be estimated as the diametric size of the joinedregion 21.

In this embodiment, the peak frequency threshold value C2, as theboundary condition, is determined based on the peak frequency fp0 of theobserved reflected wave in the case in which the ultrasonic waveincident position is located over the non-joined region 28. Morespecifically, the peak frequency threshold value C2 is set at afrequency lower than an average D2 of the reference peak frequency fp0,by a value greater than a standard deviation σ of the reference peakfrequency fp0, wherein the standard deviation σ is calculated from thereference peak frequency fp0 of the non-joined region 28.

The reference peak frequency fp0 corresponds to a frequency of the waveform at which the amplitude becomes the maximum, among the wave formsanalyzed for each frequency distribution of the observed reflected wave.The average D2 and the standard deviation a of the reference peakfrequency fp0 may be measured in advance, or otherwise calculated basedon information provided from the frequency conversion unit 100 prior tomeasurement of the frequency feature due to the frequency featuremeasuring unit 43. In this case, the frequency feature measuring unit101 measures the peak frequency fp of the observed reflected wave. Thejoined region estimation unit 37 serves to estimate the scanningposition, in which the peak frequency fp of each scanning position islower than the predetermined peak frequency threshold value C2, as aposition over the joined region 21.

Similarly, also in the case of using the central frequency fc in placeof the peak frequency fp, the joined region 21 can be estimated. Morespecifically, in the case of scanning the ultrasonic probe 31 in thescanning direction such that it can pass through the center of thejoining mark 29 as shown in FIG. 3(1), the scanning position, in whichthe central frequency fc of each scanning position is lower than apredetermined central frequency threshold value, can be estimated as aposition over the joined region 21. The central frequency thresholdvalue is used as a reference of the boundary condition for judgingwhether or not the scanning position is located over the joining region21, and is set lower than the central frequency fc0 of the observedreflected wave in the case in which the ultrasonic wave incidentposition is located over the non-joined region 28.

In addition, the scanning position P1 in which the central frequency fcof each scanning position is switched from a state higher than thecentral frequency threshold value to a state lower than the samethreshold value and the scanning position P2 in which the centralfrequency is switched from the state lower than the central frequencythreshold value to the state higher than the same threshold value can beestimated as positions over the boundary between the joined region 21and the non-joined region 28, respectively. Furthermore, the length ofthe line connecting the two scanning positions P1, P2 over therespective boundary positions can be estimated as the diametric size ofthe joined region 21.

In this embodiment, the central frequency threshold value as theboundary condition is determined based on the observed reflected wave inthe case in which the ultrasonic wave incident position is located overthe non-joined region 28. More specifically, the central frequencythreshold value is set at a frequency lower than an average of thereference central frequency fc0, by a value greater than a standarddeviation σ set for the reference central frequency fc0.

The reference central frequency fc0 corresponds to a frequency as thecentre of the frequency bandwidth between the highest frequency and thelowest frequency of the wave forms having amplitudes greater than apredetermined value, among the wave forms analyzed for each frequencydistribution of the observed reflected wave. The average and thestandard deviation σ of the reference central frequency fc0 may bemeasured in advance, or otherwise calculated based on informationprovided from the frequency conversion unit 100 prior to the measurementof the frequency feature by the frequency feature measuring unit 43. Inthis case, the frequency feature measuring unit 101 measures the centralfrequency fc of the observed reflected wave. The joined regionestimation unit 37 serves to estimate the scanning position, in whichthe central frequency fc of each scanning position is lower than thepredetermined central frequency threshold value, as a position over thejoined region 21.

FIG. 16 is a diagram for illustrating changes of the bandwidth relativeto changes of the scanning position. FIG. 16(1) is a graph illustratingthe changes of the bandwidth relative to the changes of the scanningposition, and FIG. 16(2) is a section of the joined object correspondingto the graph of FIG. 16(1). In FIG. 16(1), the scanning position isexpressed on the horizontal axis, while the bandwidth is designated onthe vertical axis. In the case in which the ultrasonic probe 31 isscanned in the scanning direction such that it can pass through thecenter of the joining mark 29 as shown in FIG. 3(1), the scanningposition, in which the observed bandwidth B of each scanning position islower than a predetermined bandwidth threshold value C3, can beestimated as a position over the joined region 21, as shown in FIG.16(1). The bandwidth threshold value C3 is used as a reference of theboundary condition for judging whether or not the scanning position islocated over the joining region 21, and is set wider than the observedbandwidth B0 of the observed reflected wave in the case in which theultrasonic wave incident position is located over the non-joined region28.

The scanning position P1 in which the observed bandwidth B of eachscanning position is switched from a state narrower than the bandwidththreshold value C3 to a state wider than the same threshold value C3 andthe scanning position P2 in which the observed bandwidth B is switchedfrom the state lower than the bandwidth threshold value C3 to the statehigher than the same threshold value C3 can be estimated as positionsover the boundary between the joined region 21 and the non-joined region28, respectively. Furthermore, the length of the line connecting the twoscanning positions P1, P2 over the respective boundary positions can beestimated as the diametric size of the joined region 21.

In this embodiment, the bandwidth threshold value C3 as the boundarycondition is determined based on the observed reflected wave in the casein which the ultrasonic wave incident position is located over thenon-joined region 28. For instance, the bandwidth threshold value C3 isset at a bandwidth greater than an average D3 of the reference bandwidthB0, by a value greater than a standard deviation σ of the bandwidth,wherein the standard deviation σ is calculated from the bandwidth of thenon-joined region 28. Alternatively, for instance, the bandwidththreshold value C3 is set at a bandwidth wider than the referencebandwidth B0 by a preset amount. As one example, it is set at abandwidth wider than the reference bandwidth B0 by approximately 1.2MHz. In this case, the reference bandwidth B0 corresponds to a frequencybandwidth of the wave form greater than amplitude lowered, by a presetamount, for example 6 dB, from amplitude of the wave form of thereference peak frequency fp0.

The observed bandwidth B corresponds to a frequency bandwidth of thewave form greater than amplitude lowered, by the preset amount, forexample 6 dB, from amplitude of the wave form of the corresponding peakfrequency fp1. The reference bandwidth B0 may be set in advance, orotherwise calculated based on information provided from the frequencyconversion unit 100 prior to the measurement of the frequency feature bythe frequency feature measuring unit 43.

For example, the frequency feature measuring unit 101 measures theobserved bandwidth B of the observed reflected wave. In this case, thejoined region estimation unit 37 serves to estimate the scanningposition, in which the observed bandwidth B of each scanning position iswider than the predetermined bandwidth threshold value C3, as a positionover the joined region 21.

As described above, in the third embodiment, the joined region 21 isestimated based on the frequency feature of the observed reflected wave,rather than on the echo level H. As discussed above, the frequencyfeature may be either one of the peak frequency fp, central frequency fcand observed bandwidth B. Furthermore, the joined region 21 may beestimated based on the other frequency features of the observedreflected wave. In the third embodiment, although only the boundarycondition for estimating the joined region 21 is different from thefirst embodiment, the method for estimating the joining strength can beperformed in the same manner as in the first embodiment. Other thanestimating the diametric size of the joined region 21 as with the caseof the second embodiment, the joining strength may be estimated byobtaining the area of the joined region 21. Also in the thirdembodiment, the same effect as that of the first embodiment can beobtained.

Due to the frequency analysis, even in the case in which the echo levelis considerably low or in the case in which noise is conspicuous, thejoined area 21 and the joining strength can be precisely estimated.Besides, due to a significantly greater change that can be measuredbetween the joined region 21 and the non-joined region 28, the joinedarea 21 and the joining strength can be estimated with higher precision.The influence of the noise may be further reduced by providing a filterfor cutting unwanted or undesired frequencies.

Due to the estimation of the joined region 21 based on the peakfrequency fp or frequency bandwidth B, the joined region 21 can beestimated, even in the case in which the frequency distribution of eachwave form included in the observed reflected wave is shifted to someextent from a normal distribution. Furthermore, with the determinationof the boundary condition for estimating the joined region 21 based onthe standard deviation σ of the peak frequency fp and/or centralfrequency fc, there is no need for setting an additional parameter, forexample, the plate thickness of the upper plate 22 or the like, for eachjoined object 20, as such facilitating the determination of the boundarycondition.

FIG. 17 is a graph for illustrating the estimation method of a fourthembodiment of the present invention. In FIG. 17, the scanning positionis expressed on the horizontal axis, while the echo level is designatedon the vertical axis. More specifically, in FIG. 17, a percentage of theecho level for each scanning position relative to the reference echolevel H0 is expressed on the vertical axis.

In the first and second embodiments of the present invention, the sizeof the joined region 21 is first obtained, and the joining strength isthen obtained based on the size. However, in the fourth embodiment ofthis invention, without obtaining the size of the joined region 21, thejoining strength is directly estimated based on the echo level extractedfrom the observed reflected wave. In the fourth embodiment, thecomputing procedure of the joined region estimation unit 37 is differentfrom that of the first embodiment. However, since the other constructionis substantially the same as that of the first embodiment, it will notbe detailed below.

In the fourth embodiment, an area 113 is obtained by integrating adistance or difference between an echo level 110 of each scanningposition and a preset echo level C4 along a range or interval 112 of thescanning position except for a scanning position 111 in which the pinportion was plunged. In this embodiment, the reference echo level H0 isset as the preset echo level C4.

In this case, with decrease of the reflected wave reflected from theinterface 27 between the upper plate 22 and the lower plate 23, the echolevel is also deceased. Namely, increase of the area 113 means increaseof disappearance of the interface 27, i.e., increase of the joiningstrength. Accordingly, the area 113 has a one-to-one relationship withthe joining strength. Thus, based on such a relationship, the joiningstrength estimation unit 38 can estimate the joining strength. While, inthis embodiment, changes of the echo level is integrated, the joiningstrength may be directly determined, based on an integrated value ofchanges of other features of the observed reflected wave, including theaforementioned peak frequency fp, central frequency fc, preset bandwidthB and the like. Also in such a case, the joining strength can bedirectly determined, based on the integrated value obtained byintegrating each changing amount of the feature's value along theinterval 112 of the scanning position except for the scanning position111 in which the pin portion was plunged.

Alternatively, the joined region estimation unit 38 may obtain theposition of the joined region 21 based on a changing amount of theobserved reflected wave relative to the change of the scanning position.For instance, in the case in which the changing amount of the feature'svalue of the observed reflected wave relative to the change of thescanning position is relatively steep, the scanning positioncorresponding to such a steep change may be estimated as a positionlocated over the boundary position between the stir-joined region 21 cand the pressure-joined region 21 d. Alternatively, the scanningposition, in which an inclination of a change of the feature's value ofthe observed reflected wave, or a value obtained by differentiating thechange of the feature's value becomes greater than a predeterminedvalue, may be estimated as a position located over the boundary positionbetween the stir-joined region 21 c and the pressure-joined region 21 d.In this way, by obtaining the shapes of the stir-joined region 21 c andpressure-joined region 21 d and adding the result to the estimation ofthe joining strength, further accurate joining strength can be obtained.

In such a manner, the joining strength of the joined object may beestimated, based on an integrated feature's value of the observedreflected wave along a unit range including a region located over thejoined region 21 as well as on a relation of conversion which is set forconverting the feature's value into the strength of the joined object,after taking in the reflected wave of the ultrasonic wave over the unitrange. If the incident region of the ultrasonic wave is limited to aunit range, the integrated feature's value will be a value of a featureof the observed reflected wave taken in from the unit range.

FIG. 18 is a perspective view showing one example of the ultrasonicprobe 31 used in the first to fourth embodiments. In these embodiments,a phased array ultrasonic probe of a one-dimensional array oscillatortype is used as the ultrasonic probe 31. The phased array ultrasonicprobe 31 is an array-type probe in which microscopic oscillators arearranged in large numbers, and is adapted to shift timing of theultrasonic wave generated from each oscillator by changing timing of apulse applied to each oscillator, as such optionally changing a focusingposition of the ultrasonic wave. Thus, there is no need for scanning theultrasonic probe in the respective array directions, thereby enhancingthe working efficiency.

Alternatively, a phased array ultrasonic probe of a two-dimensionalarray oscillator type can also be used. In addition, the ultrasonicprobe 31 of a single-probe type can also be employed. Alternatively, theultrasonic probe of a two-probe type composed of a probe adapted forgenerating the ultrasonic wave and a probe adapted for taking in theultrasonic wave may also be used. Rather than using a point-focusingtype probe, a non-focusing type probe can also be used. Alternatively,rather than introducing or radiating the ultrasonic wave vertically tothe backing face 25, the ultrasonic wave may be introduced obliquely tothe backing face 25.

FIG. 19 is a perspective view showing an ultrasonic probe 200 related toa fifth embodiment of the present invention. FIG. 20 is a diagramshowing a relationship between the scanning position and the echo level.FIG. 20(2) is a graph showing changes of the echo level relative tochanges of the scanning position, and FIG. 20(1) is a sectioncorresponding to the graph of FIG. 20(2). In the fifth embodiment ofthis invention, the construction of the ultrasonic probe 200 isdifferent from that of the first embodiment. In addition, the joinedregion estimation unit 37 is eliminated, and the joining strengthestimation unit 38 is configured to directly estimate the joiningstrength based on the echo level. Because the remaining construction isthe same as that of the previous embodiment, it will not be detailedbelow.

The ultrasonic probe 200 is achieved by a linear focusing type probe. Inthe ultrasonic probe 200, a linear ultrasonic wave introducing region201 having a length longer than the diametric size of the joined region21 is formed and a transmitter oscillator 202 and a receiver oscillator203 are provided separately. The ultrasonic probe 200 of this embodimenthas an oscillator size of 10×2 mm, and generates an ultrasonic wavehaving a frequency of 10 MHz. In this case, the echo level measuringunit 36 measures an integrated echo level of the observed reflected wavereflected in the vicinity of a position along the reference directioncorresponding to the interface 27 between the upper plate 22 and thelower plate 23.

By using such an ultrasonic probe 200, as shown in FIG. 19, theintegrated echo level, when the ultrasonic wave introducing region 201is located such that it can pass through over the center of the joiningmark 29, is obtained. In other words, as shown in FIG. 20, by scanningthe ultrasonic probe 200, the ultrasonic scanning position in which theintegrated echo level becomes the minimum is searched.

FIG. 21 is a graph showing a relationship between tensile shear strengthand a lowering amount of a relative echo level. In FIG. 21, a rate of anintegrated minimum echo level, at which the echo level is the minimum,relative to an integrated reference echo level in the case in which theultrasonic wave is introduced into the non-joined region 28, is shown asthe lowering amount of the relative echo level. In FIG. 21, a loweringamount of the relative echo level is expressed on the horizontal axis,while the tensile shear strength of the joined object obtained by adestructive inspection is designated on the vertical axis. As shown inFIG. 21, the lowering amount of the relative echo level has asubstantially one-to-one relationship with the joining strength.Accordingly, if the integrated minimum echo level is obtained inadvance, the joining strength can be directly estimated by substitutingthe obtained integrated minimum echo level into a relational equationfor calculating the joining strength. This relational equation can beobtained in advance by an experiment or the like.

In this manner, the joining strength estimation unit 38 can directlyestimate the joining strength based on the integrated minimum echolevel. While, in this embodiment, the ultrasonic probe is achieved byusing the linear focusing probe, a similar effect can also be obtainedby employing a non-focusing type ultrasonic probe. In such a case, it ispreferred that an area of the ultrasonic wave introducing region of thenon-focusing type ultrasonic probe is sufficiently larger than the areaof the joined region 21.

In this embodiment, the joining strength of the joined object can beestimated, based on an integrated feature's value of the observedreflected wave along a unit range including a region located over thejoined region 21 of the joined object 20 as well as on a relation ofconversion which is set for converting the feature's values into thestrength of the joined object, after introducing the ultrasonic waveinto the joined object from the backing face 25 of the joined object 20while taking in the reflected wave of the ultrasonic wave introducedinto the joined object over the unit range. Consequently, there is noneed for estimating the size of the joined region 21, therebyfacilitating the estimation of the joining strength of the joined object20.

In the case of using the linear focusing type probe, the ultrasonicprobe may be scanned in one direction. Alternatively, in the case ofusing the non-focusing type probe, the ultrasonic probe may not bescanned. Consequently, the estimation apparatus can be simplified, thusfacilitating the estimation of the joining strength. In addition, theintegrated feature's value of the observed reflected wave in the unitrange may be obtained by scanning the focusing type probe over the unitrange as described above. In this case, the integrated feature's valuemeans a value obtained by adding together the feature's values of theobserved reflected wave for each scanning position in the unit range oran average value of the feature's values of the observed reflected wavefor each scanning position in the unit range. While, in this embodiment,the joining strength is obtained based on the integrated changing amountof the echo level along the unit range, the scanning strength may bedirectly determined based on changes of other features of the observedreflected wave, including the aforementioned peak frequency fp, centralfrequency fc, preset bandwidth B and the like.

As stated above, the aforementioned estimation method of the joinedregion 21 and/or joining strength was described only by way of example,but may be modified without departing from the scope of this invention.For example, in each embodiment, the joined region 21 may be estimatedby employing other features of the observed reflected wave than thosedescribed above. Alternatively, the joined region 21 may be estimated bycombining together the aforementioned features of the observed reflectedwave. For instance, to enhance a factor of safety, the minimum value ofthe joining strength estimated by two or more of the estimation methodsdescribed above may be employed as the estimated joining strength. Whilethe ultrasonic probe is scanned in the embodiment described above, theoperation is not limited to this aspect. For instance, in the case ofestimating whether or not the ultrasonic wave incident position is overthe joined region 21, the ultrasonic probe may also be spotted.

While, in the embodiment above, the boundary condition of the observedreflected wave for estimating the joined region 21 is determined basedon the observed reflected wave in the case in which the ultrasonic waveincident position is located over the non-joined region 28, thedetermination of the boundary condition is not limited to this aspect.For example, the boundary condition may be set at a constant value.While, in the embodiment above, the joined region 21 and/or joiningstrength is estimated in accordance with a computing equation, thejoined region 21 and/or joining strength may be estimated by using adata base in place of the computing equation.

As one modification, in the step of measuring the reflected wave in eachof the above embodiments, as shown in FIGS. 22(1) to 22(4), theultrasonic wave may be introduced into the joined object at a pluralityof different angles of refraction from the ultrasonic probe 300. Thismethod is effective in particular in the case in which a hookingphenomenon occurs in the joined portion upon the friction stir joiningprocess. The hooking phenomenon means that the joining members 22, 23are softened upon the friction stir joining process, and the interfacebetween the joining member 22 and the joining member 23 is drawn towardthe tool plunging face 24, as such forming a curved portion (or hookingportion) 50 as shown in FIG. 22(1).

Such a hooking portion 50 does not substantially contribute to thejoining strength between the joining member 22 and the joining member23. A degree of generation of such a hooking phenomenon depends on theconditions of the friction stir joining process, including materials ofthe joining members and the like.

Due to the introduction of the ultrasonic wave from the ultrasonic probe300 into the joined object 20 with the plurality of different angles ofrefraction employed in the step of measuring the reflected wave, areflected echo from the hooking portion 50 can be caught by an anglebeam method, even in the case in which the hooking portion 50 exists inthe joined object 20. Namely, if the angle of refraction is only 0°(i.e., in the case of vertical injection), the reflected echo from thecurved hooking portion 50 can not be caught. Therefore, the hookingportion 50 that does not substantially contribute to the joiningstrength can not be distinguished from another portion that contributesto the joining strength, thus evaluating the joining strength of thejoined object 20 unduly higher than an actual value.

However, in the aforementioned example of this invention, by employingthe angle beam method of the angle of refraction of, for example, 20° or30°, the reflected wave from the hooking portion 50 can be caught. Thus,the joining strength can be precisely estimated even in the case inwhich the hooking portion 50 exists in the joined object 20.

FIG. 23 is a diagram for illustrating a measuring method employing theultrasonic probe 400 composed of a vertical oscillator, the method beinga sixth embodiment of the present invention. FIG. 24 is a graph showinga relationship between a joined region diameter and the echo level inthe measuring method according to the sixth embodiment of the presentinvention.

In this embodiment, an ultrasonic beam having a cross section greaterthan the joined region diameter is introduced into the joining member 22by using the ultrasonic probe 400 composed of the vertical oscillatorwhile the reflected wave of the ultrasonic wave introduced into thejoining member 22 is taken in the ultrasonic probe 400 (Reflected wavemeasuring step). The ultrasonic beam radiated from the ultrasonic probe400 is introduced into the joining member 22 through an ultrasonicpropagator 401 located between the ultrasonic probe 400 and the joiningmember 22.

In this embodiment, the joining strength of the joined object 20 isestimated based on the reflected echo level obtained by the reflectedwave measuring step (Strength estimation step). Namely, by measuring inadvance the relationship between the joined region diameter of thejoined object and the echo level as shown in FIG. 24, the joined regiondiameter can be estimated by measuring the echo level even in the caseof the joined object 20 having an unknown joined region diameter.

In this way, according to the above embodiment, the joining strength canbe directly estimated without estimating the area of the joined region,and the joining strength of the joined object 20 can be estimated with asimple and low-cost method.

It is contemplated that the testing method and the testing apparatusemploying the estimation method of the first embodiment are included inthe present invention, and that the testing methods and the testingapparatuses employing the estimation methods of the second to sixthembodiments are also included in the present invention. Namely, also inthe second to sixth embodiments, the quality of the joined object can beinspected, without destroying the joined object, by judging whether ornot the joined object can satisfy a predetermined quality, based on anobtained estimation result.

In addition, a case of displaying the estimation result obtained byestimating the joined region 21, by using the display 40, withoutestimating the joining strength, is also included in the aboveembodiment. Furthermore, an inspector may judge the joining qualityincluding the joining strength or the like, by displaying an imageshowing the shape of the joined region 21 on a two-dimensional plane.While, in the above embodiment, the estimation apparatus 30, 130performs the estimation of the joining region 21 and/or the joiningstrength, the estimation method is not limited to this aspect. Forinstance, an estimation method in which a person conducts theaforementioned steps is also within the scope of this invention. Whilethe joined region 21 is estimated in the above embodiment, thestir-joined region 21 c and the pressure-joined region 21 d may beestimated, instead, individually, in the same procedure. While, in theabove embodiment, the upper plate 22 and the lower plate 23 arerespectively formed from an aluminum alloy, the joined object 20 may beformed from any other suitable materials, provided that these materialscan be joined by the friction stir joining method. In addition, as theultrasonic probe, a general purpose device may be used.

As stated above, while preferred examples of this invention have beenshown and described specifically to some extent, it is obvious thatvarious modifications can be made thereto. Accordingly, it should beunderstood that the present invention can be implemented in variousaspects different from those specifically shown and described hereinwithout departing from the scope and spirit of the claimed invention.

The invention claimed is:
 1. A method of estimating a joining strengthof a joined object in which two joining members are joined togetherwhile being overlapped one on another by using a spot friction stirjoining method, comprising: introducing an ultrasonic beam, by using avertical oscillator, into a joined region of the joined object from aface of the joined object opposed to a plunging face thereof in which ajoining tool was plunged during a friction stir process, the beam havinga cross section at a surface of the joined object that is larger than adiameter of the joined region at the plunging face; taking in areflected wave of the ultrasonic beam introduced into and reflected fromthe joined object; and estimating the joining strength of the joinedobject, based on a reflected echo level obtained by measuring thereflected wave.
 2. A method of testing a joined object in which twojoining members are joined together while being overlapped one onanother by using a friction stir joining method, the testing methodcomprising the step of inspecting the joined object based on anestimation result obtained by the estimation method according toclaim
 1. 3. A method of estimating a joint strength, the methodcomprising: providing a joined object having two overlapping membersthat are joined together in a mutually overlapping region by using spotfriction stir joining, where a joining tool forms a joined a joinedregion at a plunging face of the joined object; introducing anultrasonic beam from a vertical oscillator into the joined region from aface of the joined object opposite the plunging face, the beam having across section dimension that is greater than all dimensions of thejoined region; measuring a reflected echo level of a reflected wave ofthe ultrasonic beam; and estimating the joint strength of the joinedobject based on the reflected echo level.
 4. The method of estimating ajoint strength according to claim 3, wherein for purposes of comparisonwith the dimensions of the joined region, the beam is measured at asurface of the joined object.